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INDUSTRIAL VISIT TO
KUDANKULAM NUCLEAR POWER PLANT
KUDANKULAM, TIRUNELVELI DISTRICT, TAMIL NADU
arranged by
INSTITUTE OF LOSS ADJUSTERS
on
01.12.2012
PRELUDE
the 17 reactors in operation and 5 under construction, which dot the map of India. The core business
at NPCIL is power generation. The Company generates about 3% of the total electricity generated in
our country.
INSTITUTE OF LOSS ADJUSTERS, Chennai (ILA) had arranged for an Industrial Visit to the surveyors
and loss assessors for visiting the KUDANKULAM NUCLEAR POWER PROJECT (KKNPP) which is under
construction by the NPCIL. KKNPP is located in Tirunelveli District but is very near to Kanyakumari.
The most advanced VVER-1000 reactors in the plant are designed by Russian Engineers & Scientists
that would generate 1000 Mega Watts each. Out of the two reactors, one unit is almost completed
and is expected to commence commercial production by December, 2012. The other one is under
construction. Four more units of similar capacities are also proposed in Kudankulam.
The number of visitors was limited to 50 by the KKNPP. All the participants were required to submit
their names, SLA No., age, address in advance of the visit for registration with KKNPP and were also
asked to bring in person their original photo identity card at the time of visit. As required in any
industrial visits, the participants were asked to come in formal dress code and wearing shoes. The
ILA started registering the participants and upon reaching the maximum number of participants by
28.11.2012, the registrations were closed. In order to maintain the first-come-first-served policy
without any deviation, the registrations were made over cloud computing system with volunteers at
three different locations but working on a single platform on the cloud. The details of the
participants were mailed to the KKNPP authorities on the same day and their approval was obtained
Thereafter each of the participants were individually called over phone by the organizers and certain
formal data and confirmation were sought from the participants. Participants were also informed of
the maxicabs arranged for the travel to KKNPP from Tirunelveli and Nagerkovil and were asked to
arrive at the scheduled locations at the scheduled timings for pickup like Railway Station, Bus Stand,
While the maxicab from Tirunelveli moved towards KKNPP at around 7:30 AM, the other one from
Nagerkovil started at 8:30 AM and headed towards KKNPP. Both reached along with the other cars
atleast half-an-hour ahead of the time schedule fixed for the visit at 10 AM. The whole locality was
like a curfew area with a lot of armed police personnel, reserve police and CISF police personnel
keeping a vigil. Barricades, heaps of sand bags, shelters, bunkers, etc. provided on the approach
road from the main road till the main gate of the plant added terror to the visitors. From the
outside, we could see the administrative block, power plant block and a lot of wind mills inside the
campus. After a formal identity verification by CISF personnel, all the 47 participants (three were
absent) were boarded on to a bus inside the plant compound and the journey inside the plant
commenced.
BRIEFING AND LECTURE ON KKNPP
Sharply at 10:30 AM, we were all guided into a neatly furnished and air-conditioned auditorium
where an animation film about the necessity of a nuclear power plant and basic safety features was
shown. The short film of about 20 minute duration added more curiosity of visiting the plant.
Mr. Pandaram, Deputy Chief Engineer who had served in the National Power Corporation of India
Limited in various atomic power stations and now deputed to KKNPP was kind enough to give a brief
lecture on the conventional sources of electrical power generation like hydel power projects,
thermal power projects, wind mill projects, solar power projects and outlined as to how nuclear
energy is superior and cheaper and at the same time a safer system.
After a break for tea, we were taken to the full scope training simulator where the training
programmes at different levels are conducted for qualifying and licensing of operating personnel, as
per the regulatory requirements. Training simulators are used to provide training in all aspects of
operation, including handling of unusual incidents. Key operations personnel are also imparted
rigorous training in various systems of the plant on training simulators before being actually deputed
to man the control systems. It consisted of a lot of large format display units showing the outputs
from various sensors and sources such as temperature, pressure, quantity of flow and various such
other parameters.
Thereafter we were guided to a hall where a model of the whole plant was available. We were
explained about the various blocks forming the plant, where the containments where the nuclear
reaction take place, the location of generators, location of diesel generators for safe shutdown and
The locational advantage and geographical safety of the plant was enumerated by explaining about
the seismological facts and figures comparing to that of the Fukushima NPP in Japan.
The technical details of the raw material used in the nuclear reactor, viz., Uranium and the
comparison of a nuclear power plant to that of a thermal power plant was elaborated. The basic
operation of a nuclear power plant is no different from that of a conventional thermal power plant
that burns coal or oil or gas. Both heat water to convert it into pressurised steam, which drives a
turbine to generate electricity. The key difference between the two plants lies in the method of
heating the water. While the conventional power plants burn fossil fuels to heat the water, in the
nuclear power plant, this heat is produced by a nuclear fission reaction, wherein energy in the
In this plant, the main fuel used is Uranium 235 which is presently imported. But Uranium deposits
are found in plenty in India in the Western coasts, particularly in Kerala. The fuel assembly has 311
fuel rods of each 3.5 metres long. Each fuel rod contains about 350 fuel pellets which are of the size
of an eraser at the other end of a pencil. Therefore one fuel assembly contains about 1,08,850
pellets. The fuel assemblies are loaded into the reactor in a particular geometrical fashion along
with other monitoring and controlling equipments. This part of the reactor vessel is known as
reactor core, which is the source of heat energy for production of steam in the reactor. The reactor
power is controlled by means of control rods that reduce the fission reaction when inserted into the
core. In case of an emergency, all the control rods will fall into the core by gravity and the time
taken or this is only 4 seconds, i.e., to stop the nuclear fission reaction. Thereafter the core has to
how the heat energy developed is utilized to generate steam and thence the steam turns the turbine
coupled to the generator, in order to generate electrical power. The power thus generated is fed to
the grid for further transmission. Due explanations were also made about the safety of the plant in
terms of impacts such as impact by missiles, air-planes and the like, by tsunami, by earthquake and
such other natural calamities. The primary containment (dome) has a wall thickness of 4 feet which
is of reinforced pre-stressed concrete. The inner containment or the secondary containment is also
of reinforced concrete with a wall thickness of 2 feet. The gap in-between the layers is nearly 6 feet.
The whole structure ensures that no leakage of any radioactivity takes place to the environment.
We were also enlightened about the Passive Heat Removal System (PHRS) which is a unique design
Here a comparison was made with the KKNPP reactors to that of Fukushima reactor. The Fukushima
reactor breakdown was triggered by a very rare natural event — the occurrence together of an
earthquake of magnitude 9 on the Richter scale and a 15-metre tsunami which completely
overwhelmed the plant and its safety systems. Although the physical structure of the Fukushima
plant withstood the earthquake, together with the tsunami, the earthquake led to the loss of offsite
and onsite power leaving the plant completely dependent on diesel generators and batteries of
emergency cooling system for reactors. But adequate emergency power was not available at
hydrogen that exploded rupturing the containment structure within a matter of hours and
But in the case of KKNPP's reactors, we were informed that the PHRS is a passive system where the
containment is cooled by natural means independently without the intervention of any power
related safety systems. This is in addition to the various in-built safety systems such as insertion of
control rods by gravity to stop the fission in case of any emergency/disaster. To cool the reactor,
water accumulators are kept inside the reactor building itself in order to pour water with boron into
the reactor. Apart from that four diesel generators that pump out the coolant to cool the reactors
are also provided. In a hypothetical event if all the safety system fails and the reactor core starts
melting due to the enormous heat, the molten core would be confined to a core catcher within the
containment boundaries.
About the spent fuel storage, which is a prime concern of environmentalists and public, the officials
explained that one-third of the fuel rods would require to be removed (by robots - as no human can
enter into the containment) and the fuel rods need to be cooled in a pool of water for six to seven
It was by then time for lunch and we were guided to the very spacious industrial canteen where
After lunch, we were taken in a bus to one of the reactor containment. As the other one is ready for
power generation, it has been sealed with tight security round the clock and no outsiders are
allowed.
The civil works were all complete and the fixing of the pressure vessels and core works were being
done. It was a great opportunity for all the 47 people to enter into the place where the actual
nuclear reaction would take place. The feelings cannot be expressed just in words. It has to be
actually felt.
As the fabrication works were under progress and massive structures being moved by means of jig
cranes, it was worth a sight for all. We were on a metal platform inside the containment at
27 metres high from the ground level. From the containment, viewing the sea on the other side was
a wonderful sight.
Inside the containment, we were explained by Mr. Selvaraj and Mr. Vinayagamoorthy, personnel of
KKNPP about the various equipments and their functions. After about an hour, we came out of the
turn in low pressure and high pressure for getting a uniform revolution of the turbine and thus the
generator.
After this, we were taken in a bus to the fish protection facility, which is a big pond built inside the
sea to draw sea water for cooling the reactor, steam pipes and turbines. Sea water is drawn from a
forced air bubbles up the sea water diverting the fishes upwards and water is drawn at a depth of 13
Since photography by visitors are prohibited being a high security place, photographs are certain
locations were taken by Mr. Vinayagamoorthy. They have assured to send the photographs to the
organizers.
the opportunity of interacting with Mr. Pandaram who again took us to the
radio-active testing lab and other such facilities available. He also took us
to the library where he distributed several books about the plant, nuclear
energy, safety aspects, a wonderful book written by Dr. A.P.J. Abdul Kalam,
the gate. After the formal security inspection, individually, we came out of the plant, went to our
respective vehicles, took our own cameras and mobiles, which were safely kept under specially
arranged watch and ward system in individual named packs (Thanks to Mr. P.L. Sivakumar for the
nice arrangement) and started taking pictures outside the plant and the picturesque surroundings
The maxicabs and the cars started their return journey by around 6 PM to their respective
destinations.
We are grateful to the core organizer of the whole episode, Mr. T.M. Renganathan, Surveyor from
Nagerkovil (Kanyakumari District), without whose efforts, the permission for the visit could not have
been obtained.
Thanks a lot to him, and a lot of thanks to KKNPP management for giving us the permission to the
visit and our heartfelt thanks to all the officials of KKNPP who were so kind enough to explain us
every minute detail about the plant and the high level of hospitality shown to us from the time of
seeking appointment for the visit till completing the visit. THANKS, THANKS and THANKS TO ALL THE
PARTICIPANTS who showed their dignity and professionalism throughout the visit. Thanks to each
and everyone who made this visit a very useful one, a knowledgeable one and a most memorable
one and an opportunity that one may rarely get another time.
Issued by:
INSTITUTE OF LOSS ADJUSTERS
Admn. Office, 18, Arthi Chambers,
189, Anna Salai, Chennai - 600 006.
E-mail: ila.group@gmail.com